Composites Recycling Made Easy - EuCIA · Composite materials are designed to provide mechanical...

Composites Recycling Made Easy

we knowTHE WORLD OF COMPOSITES


3COMPOSITES RECYCLING MADE EASY

Composite solutions that last Composite materials provide solutions for mechanical strength and protection in many market segments such as transportation, electrical, building and infrastructure, industrial and energy. These materials have a track record of providing useful benefits including high durability, mechanical performance, design freedom, low weight, and ease of manufacturing.

Composites can be easily recycled. Additionally, composites have demonstrated to often have a better Ecological footprint than traditional materials like steel, aluminium and concrete. This brochure provides an insight into the established recycling routes for composites, and their positive impact on the environment.

COMPOSITES RECYCLING MADE EASY4

Recycling of Composites makesbusiness sense and it is environmentally beneficial

The recycling of glass fibre reinforced thermosets has been studied extensively since many years. Fundamentally, three recycling technologies have been researched and yield potential waste management solutions: material recycling, chemical recycling and co-processing. Co-processing composites through the cement kiln route is considered the best recycling option (Reference: Joint industry position paper on Glass fibre reinforced thermosets: recyclable and compliant with the EU legislation, June 2011, by EuCIA, ECRC, EuPC, Cefic”.

The recycling of glass fibre-based composite regrind through co-processing in cement kilns is proving to be highly cost effective, is generating valuable materials, and is helping to improve the ecological footprint of cement manufacturing. For these reasons, this recycling route is becoming increasingly popular across Europe.

Co-processing is the simultaneous use of composite regrind as raw material and as a source of energy in cement manufacturing, to replace natural mineral resources (material recycling) and fossil fuels such as coal, petroleum and gas (energy recovery). In this process, the composites regrind used for co-processing is both an alternative fuel and raw material (AFR).

Fig.1 : Unloading of windmill blades atprocessing siteCourtesy: Zajons, Melbeck

Composites recycling throughCo-Processing: technically possible and cost effective

Glass fibre thermoset composite parts - originating from part manufacturing or end-of-life components - are cut in smaller sections and processed into small chunks. The resulting regrind is combined with other feedstock materials into an input stream with consistent composition and caloric value.

Fig.2 : Part storage prior to mechanical treatment Courtesy: Zajons, Melbeck

Fig.3 : Mobile sawing equip-ment to reduce transport costsCourtesy: Zajons, Melbeck

Fig.4 : Typical composite regrind, made from ground windmill bladeCourtesy: Zajons, Melbeck


European recognition for composites recycling

Recently the European Commission released a Guidance document on the interpretation of Waste Framework Directive WFD 2008/98/EC. The document is intended to help national authorities and companies interpret the Directive.

Among other specifications, co-processing in cement manufacturing is included in the definition of waste prevention and of waste-management options, both under recovery and recycling (Chapter 1.4). The Guidance notes that:

“In certain production processes such as co-processing, waste can be used in an operation combining two waste management recovery options at the same time. The energy content of the waste is recovered (R1 operation) as thermal energy, thus substituting fuels, while the mineral fraction of the waste can be integrated (hence recycled) in the matrix of the product or material produced, e.g. cement clinker, steel or aluminium […]” (Subchapter 1.4.5).

Recycling through co-processing in cement kilns has been technically and commercially demonstrated. Today, companiesare setting up logistics and supply chains for ensuring proper handling of regrind and quality consistency of cement manufacturing.

Therefore, recycling through co-processing in cement kilns is increasingly used for managing composite regrind because of its technological potential, environmental benefits and cost effectiveness.

Composite materials are designed to provide mechanical strength, chemical resistance, and durability. Consequently, by definition they cannot be easily re-converted into their original raw materials.

Composite structures tend to have a better Eco-footprint compared to their equivalent in traditional materials like steel or aluminium. Reduced emissions through lower weight in transportation, easier installation and reduced maintenance in construction, and continuity of operation in industrialapplications all contribute to this great performance.

After their useful life saving energy and helping to reduce Eco-footprint in many applications, composite regrind can reduce Eco-footprint and CO2 emissions of cement manufacturing.

Co-processing glass fibre thermoset composites regrind allows the inorganic fraction to act as valuable raw material, while the organic fraction acts as efficient fuel for the calcination process.

In the incineration of composite regrind, the inorganic fraction is not re-used, and therefore incineration cannot be considered recycling. In addition the heat generated in incineration cannot be used as efficiently to reduce the amount of fuel required.

Recycling through co-processing in cement kilns is fully compliant with the European Waste Framework Directive (WFD) 2008/98/EC providing viable waste management route for the composites industry. Co-processing is both recycling and energy recovery.

Composites are recyclable

Thermoset composites cannot be easily converted intotheir original raw materials

Composites can contribute significantly to the reduction of Eco-footprint and CO2 Emissions

Co-processing in cement kilns is clearly different from incineration

Composite recycling though co-processing in cement kilns is compliant with the EU legislation

FACTS BACKGROUND

Fig.

5 :

Fact

s ab

out

Com

posi

tes

Rec

yclin

g

Source: Guidance on the interpretation of key provisions of Directive

2008/98/EC on waste, European Commission, June 2012


Using LCA as key toolLife Cycle Assessment (LCA) is an internationally standardized methodology (ISO 14040 ff) to quantify the environmental pressures related to specific goods and services (products). The LCA results help to understand the environmental benefits, the trade-offs and areas for achieving improvements taking into account the full life-cycle of the product. (Source: European Platform on Life Cycle Assessment (LCA), European Commission)

The Ecological Footprint is a measure of how much area of biologically productive land and water an individual, population or activity requires to produce all the resources it consumes and to absorb the waste it generates, using prevailing technology and resource management practices. The Ecological Footprint is usually measured in global hectares. Ecological Footprint is often referred to in short form as Footprint. (Source: Global Footprint Network)

Carbon Footprint (CF) also named Carbon profile - is the overall amount of carbon dioxide (CO2) and other greenhouse gas (GHG) emissions (e.g. methane, nitrous oxide, etc.) associated with a product, along (parts of) its supply-chain and potentially including emissions from use and end-of-life recovery and disposal. The carbon footprint is quantified using indicators such as the Global Warming Potential (GWP). (Source: Joint Research Center, European Commission).

Embracing life cycle thinking

The European Composites Industry embraces Life Cycle Thinking (LCT) throughout its value chain with the objective of maintaining a sustainable and competitive business environment for the future.

With the support of the European Composites Industry Association (EuCIA), the composites industry is working towards the use of life cycle assessments to evaluate the environmental benefits of composite materials throughout their life cycle. The concept of Life Cycle Thinking (LCT) integrates existing consumption and production strategies towards a coherent policy making, employing a bundle of life cycle based approaches and tools.


Composites provide a lowCarbon FootprintIn January 2012, the Composite industry released an LCA study on parts made from SMC/BMC Light Weight Composites, providing a quantitative assessment of the carbon footprint and Ecological footprint of Composites with other materials. (Source: Study done by European Alliance for SMC/BMC through LCS Life Cycle Simulation GmbH).

A representative composite part (stationary application) made of different materials was evaluated during the LCA, for a useful part life with a life expectation of 30 years. To ensure the quality of the LCA study the results were reviewed by independent experts according to the requirements of International Standards (ISO 14040 and ISO 14044 standards). Some of the key model assumptions are listed in the table below.

SMC, Steel, Aluminium

1 m2 panel

Production, forming, recycling

Production, forming (1 step), surface treatment (painting), painting during service life (each 5 years), recycling

Material types

Part type used for modelling

Investigated processes (SMC)

Investigated processes (Steel, Aluminium)

KEY MODEL ASSUMPTIONS

2.25

0.80

2.20

SMC

Steel

Aluminium

MATERIAL COMPARISON THICKNESS(mm)

4.163

6.280

3.240

WEIGHT(kg)

1.85

7.85

2.70

DENSITY(g/cm3)

The results have clearly shown that composites can outperform steel and aluminium when it comes to Global Warming Potential (GWP in kg CO2-equivalent per Functional Unit). The graph below represents the outcome of such calculations.

Reduced CarbonFootprint ofComposites

Fig.6 : LCA results for a stationary application with more than 30-yrs lifetime warranty, comparing composites with steel and aluminium Courtesy: European Alliance for SMC/BMC

SMC Steel Aluminium

30

25

20

15

10

5

0GW

P in

kg

CO

2-eq

uiv-

per R

F

-54%


The process of cement manufacturingIn the cement manufacturing process several raw material fractions are combined with an energy source and heated up to 1450 °C for making cement clinkers. The clinkers consist of four basic oxides in a specific proportion: calcium oxide (65%), silicon oxide or silica (20%), aluminium oxide (10%) and iron oxide (5%). Gypsum (calcium sulphate) and possibly additional cementitious compounds (such as blast furnace slag, coal fly ash, natural pozzolanas, etc.) or inert materials (limestone) are added to the clinker. All constituents are ground into a fine and homogenous powder called cement.

By the very nature of this process, a fair amount of CO2 is generated. The Cement industry has made significant steps to improve sustainability and the carbon footprint by replacing the traditional fuels such as oil, gas and coal with alternative fuels in clinker production.

Glass fibre thermoset regrind is an ideal raw material for cement manufacturing. The mineral composition of the regrind is consistent with the optimum ratio between calcium oxide, silica, and aluminium oxide. Additionally, the organic fraction supplies fuel for the reaction heat, right at the spot where it is needed most.

Fig.7 : Typical cement manufacturing process Courtesy: Holcim

Life Cycle Assessment of Clinker Together with the Swiss Federal Institute of Technology (ETH) in Zürich, Switzerland, a detailed LCA model has been developed describing the clinker manufacturing process. The objective was to better understand the improvements that can be made in terms of carbon footprint by replacing the traditional fuels in clinker production.

Key assumptions for this specific case study on composite regrind co-processing in cement manufacturing are listed right.

Precalciner

SNCR (Selective Non Catalytic Reduction)

E-Precipitator

Kiln type

DeNOx installation

Dust filter

KLIN TECHNOLOGY

15.3 MJ / kg

87.4 kg / GJ

36.6%

Calorific Value

CO2 emission factor

Carbon Content

COMPOSITE RIGRIND CHARACTERESTICS

46.1%

0.04 kWh/kg

119 km

Ash content

Electricity consumption for waste preparation

Transport distance

26.05 MJ/ kgCoal

FUEL SUBSTITUTED


Reduced Carbon Footprint of cement by using composite regrindBy using Composite regrind in co-processing a significant reduction of CO2 emission of the clinker manufacturing process can be obtained. Depending on the quantity of composite regrind included and the specific cement plant technology, the reduction can be as high as 16 %.

Fig.8 : Reduction of CO2 footprint for this specif ic clinker manufacturing plant with glass reinforced composite regrind, in comparison to a process without alternative fuels based on coal as fuel.Courtesy: Holcim

25% composite 50% composite 75% composite0%

-2%

-4%

-6%

-8%

-10%

-12%

-14%

-16%

-18%% o

f tot

al G

loba

l War

min

g Im

pact

The transportation of composite regrind from its source to the cement kiln will obviously influence the calculation of the Eco-footprint. Nevertheless, it has been confirmed that the impact of transportation is fairly limited on the total CO2 footprint of the clinker manufacturing process.

Fig.9 : Contribution of CO2 footprint associated with composite regrind transportation as a percentage of the total CO2 footprint for this specific clinker manufacturing plant, as a function of transportation distance. Courtesy: Holcim

50 km 100 km 500 km

3.0%

2.5%

2.0%

1.5%

1.0%

0.5%

0.0%

% o

f tot

al G

loba

l War

min

g Im

pact

750 km 1000 km

-5.3%

-10.3%

-16.0%

0.4%0.5%

1.5%

2.7%

2.1%


Fig.10 : Composite recycling in process

Courtesy: Zajons, Melbeck

Significant emission reduction through use of glass reinforded composites

0.9 kg CO2-eq/kg composite 1.8 kg CO2-eq/kg resin


EuCIACommitted to SustainabilityThe European Composites Industry Association (EuCIA) aisbl and its members are committed to making Sustainability an integral part of their business strategy, simultaneously taking care of the environment, society and continued business growth in the composite value chain. The industry provides solutions for reducing carbon emissions in mobility, renewable energy, eco-friendly constructions, and sound waste management practices.

AcknowledgementEuCIA aisbl wishes to extend its thanks to Fiberline Composites, Holcim Group Support Ltd., DSM Composite Resins A.G., and Zajons Zerkleinerung GmbH, for their contributions and support drafting this brochure.

ContactsFor further information please refer to www.eucia.eu For additional questions and comments please contact us at [email protected]

Disclaimer

This publication is intended for guidance only and provided in good faith. While the information in this document is accurate as far as the authors are aware, no representations or warranties are made with regards to its completeness and no liability will be accepted for damages of any nature whatsoever resulting from the use of or reliance on the information contained in the publication. Full or partial reproduction of the information in this document is allowed, but only when mentioning EuCIA aisbl as the source and on the condition of informing EuCIA aisbl through [email protected].

Fig.10 : Composite recycling in process

Courtesy: Zajons, Melbeck



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European Composites Industry Association (EuCIA) [email protected] - www.eucia.eu

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